Winding apparatus

ABSTRACT

According to the invention, winding apparatus comprises means for rotatably mounting a parent roll of web material, a mandril adapted to receive a hollow core sleeved thereon, means for driving the mandril in rotation, clutch means for providing limited torque transfer between the driving means and the core on the mandril, a core co-operating roll mounted for rotation, the core co-operating roll and mandril being relatively movable between an adjacent co-operating web feeding position to feed web led from the parent roll between the core co-operating roll and the core on the mandril to be nipped thereby and a separated position (constituting a loading and unloading station) to allow for sleeving of the core on and removal of the core from the mandril, and means for guiding the leading edge of the web nipped by the core co-operating roll and the core on said mandril around the core; further means are provided to operate with the mandril and core co-operating roll separated to sleeve a core onto mandril preparatory to the winding of the web material thereon and to remove a wound core off the mandril following winding thereof.

[ 51 Sept. 30, 1975 United States Patent [191 Salgo ABSTRACT WINDING APPARATUS Inventor: Leslie Salgo, BOX According to the invention, winding apparatus com- Pickering, Ontario, Canada Sept. 11, 1972 Appl. No.: 288,074

prises means for rotatably mounting a parent roll of web material, a mandril adapted to receive a hollow core sleeved thereon, means for driving the mandril in 22 Filed:

rotation, clutch means for providing limited torque transfer between the driving means and the core on the mandril tation,

a core co-operating roll mounted for rothe core co-operating roll and mandril being [52] US. 242/56 R; 242/67.3 R; 242/754; 242/7545 [51] Int relatively movable between an adjacent co-operating web feeding position to feed web led from the parent Field of Search.

roll between the core co-operating roll and the core on the mandril to be nipped thereby and a separated position (constituting a loading and unloading station) to allow for sleeving of the core on and removal of the [56] References Cited UNlTED STATES PATENTS core from the mandril, and means for guiding the leading edge of the web nipped by the core cooperating roll and the core on said mandril around the core; further means are provided to operate with the mandril and core co-operating roll separated to sleeve a core onto mandril preparatory to the winding of the web material thereon and to remove a wound core off AAXRRX 66 66 55 4 //6//. 22 225 44/447 22222.4. n "4 m2 I Primary E.\'aminerEdward J. McCarthy the mandril following Winding thereof- 1 AIIOIHE), Agent, or Firm Doug as S Johnson 45 Claims, 23 Drawing Figures US. Patent Sept. 30,1975 Sheetlof 14 3,908,923

US. Patent Sept. 30,1975 Sheet20f14 3,908,923

US. Patent Sept. 30,1975 Sheet30f 14 3,908,923

US. Patant sebt. 30,1975 Sheet40f 14 3,908,923

U.S. Patfint Sept. 30,1975 SheetSof 14 3,908,923

U.S. Patant Sept. 30,1975 Sheet60f 14 3,908,923

U.S. Patent Sept. 30,1975 Sheet70f 14 3,908,923

US. Patent Sept. 30,1975 Sheet80f 14 3,908,923

US. Patent Sept. 30,1975 Sheet90f 14 3,908,923

US. Pamnt Sept. 30,1975 Sheet 10 0f 14 $908,923

US. Patent Sept. 30,1975 Sheetllof 14 3,908,923

US. Patent Sept. 30,1975 Sheet 12 of 14 3,908,923

US. Patent Sept. 30,1975 Sheet 13 of 14 3,908,923

DOWN 153 CORE l J flg E [LOADING CYLINDER CYLIN ER D 8 72 LOAD-UN- wIND- MOTOR 94 JET ING BRACKET LOAD SENSE PQSI- CYL. POSITION CYL TION FIG.'|7A 224 1 I 3 5 FIG-17D 414 ,AMASTER TURRET CYLINDER 19 BRAKE CORE PICKUP CORE LOAD m; 42 1ZOSITION POSITION METERING 524, 1/ ROLL :i

BRAKE I 84 .WINDING ROLLCLAMPCYL.

g ARBOR 167 BRAKE I I PIG/I75 FIG/WE 225 T\\ 13 P58 f P5A A q 7 T g EJECTOR CYL. I P5 RETRACT EJECT fjll l J FIG 17C DOWIE ZP P3 229 i511 M 4 fw P7 Plc ItI I E PM f m EIOWO FIG.17F

7 PRESJ LVAC POWER VALVES P1 TO P7 US. Patent $e I.30,1975 Sheet 14 of 14 3,908,923

TO POWER 2'17 214 VALVES o SUPPLY 218 T TO P7 232 216 215 213 221 z 226 219 2188 L2 F SING. L3 RV-5 i ERv-1 (L3) L4) L4 JRV-5 |RV-1 p4 cORE LOADERADVANCE" E A JET SENSORADVANCE" L5 DOWN" (L27, L28) P7 ,1 L6 cOR g AR VACUUM OFF L7 I r 2 (L) L8 A 28 226 L9 P4 cORE LOADERRETRACT" RW B JET SENSORRETRACT" L10 I I MOTOR BRACKET "UP FILM GUIDE UP L11 BRAKES "OFF" 222 W7 LOADER U TAB BLOW-OFF R SZQ I H ROLL CLAMP OPENED 13 ASSIST W2 WINDING MOTOR ON" N10 235 P? VACUUM ON 21/ L10 L17 ERW REQD LENGTH WOUND /e L19 W2 W3 MOTOR BRAcKETDOwN" KNFE UP L21 F '5: (L22) 1 KNIFEUP" L22 W RV 3 EJECT Lv-5 L23 2? 5; (L) FIG 18 L24 2V L25 EJECTOR FULL OUT tg (L22) L26 yf-fi ii (L27, L28) L27 5 TURRETDOWN" RV 4 F L ROLL CLAMPCLOSED" J2 L28 1% G (L7) L29 1 JET 1 (CORE ON ARBOR) L30 ,2 F(L7) 1 WINDING APPARATUS BACKGROUND OF THE INVENTION The winding of a web of material presents a number of difficult problems. In particular, the tension in the web must be closely controlled at all times throughout the winding cycle comprising start of wind, winding and end of wind, so that the web is not ruptured, or stretched beyond its elastic limit, or allowed to become slack, yet at the same time the winding cycle must be as short as possible for efficient economical production. If at any time during winding the web is tensioned to an excessive degree although short of actual web rupture, web distortion occurs and for instance the web becomes necked or rippled, spoiling the appearance of the wound product. If the excessive tension is such as to stretch the web beyond its elastic limit then, in the case where the intended function of the web is to act as a stretchable material to be stretched on application and then allowed to contract to provide an effective seal, the wound web has no utility.

The core on which the web is wound must be of inexpensive construction such as a hollow tube of paper or other relatively inexpensive material which inherently limits the resistance of the core to collapse under pressure. This factor creates special problems since the web material cannot be wound without tensioning same causing at least some measure of stretch and since it is essential to restrict such stretching below the elastic limit of the material the web contracts on the core as soon as it is relieved of the winding tension thereby exerting a progressively increasing pressure on the core as the winding continues tending to cause core collapse. This web memory recovery or contraction occurs while thee core is conventionally subject to lateral deflection between its end supports during winding due to web pull on the core, and leads to a high incidence of core collapse or buckling during winding, destroying the product and creating problems for its release from the winding station.

The web itself of course must be wound on the core free from start to finish of folds, creases, wrinkles or other disconformities, and the length of web wound must be held constant to the intended specified length. Apart from the matter of controlling tension in the web during the actual winding operation the severing of the tensioned web when a sufficient length of material has been wound on the core presents special problems. As will be appreciated, as the tensioned web parts it will have a backlash tendency in both directions away from the line of severance and if the trailing edge of the web material wound on the core is not controlled or the web is not uniformly tensioned, such trailing edge will either not lie symmetrically along the outside of the core or will be distorted or ragged and will not lie smooth against the outside of the core. On the other hand, if the flying leading edge of the parent web stock is not properly controlled, start of the winding of the next succeeding core either cannot be effected or, alternatively is effected, but with such leading edge either not lying uniformly along or smooth against the core. Both improper winding starts or finishes affect the acceptability of the product particularly where the web is a clear transparent material such as PVC or polyethylene.

The above problems have not been overcome by the winding machines of the prior art and their inability to control web tension and web severance has led to frequent web rupture and consequent machine function interruption and loss of product, to frequent core collapse due to web contraction with consequent machine function interruption and loss of product and to frequent web necking, wrinkling, creasing and other nonuniformities and core appearance distortion and again, loss of product.

Again, because of the inherent weakness of the economically acceptable hollow or tubular core structure, a difficult problem is presented to adequately support the core during winding in a manner which will enable the core to be delivered to and removed from the winding station. Also the requirement that the winding be controlled to wind an accurate length of web rather than to wind for a specific length of time has presented special problems in the feeding of the empty cores to and the removal of the wound cores from the winding assembly while at the same time ensuring positive core delivery and removal at the appropriate time.

When the core is wound with the requisite length of web the wound core is desirably required to be tabbed or labelled with a circumferentially extending, preferably central, tab adhered across the trailing edge of the web on the core, and to an under layer or portion of the web next adjacent the trailing edge, the tab having a free non adhered portion to be gripped by the fingers and pulled to commence roll unwinding. As will be appreciated, therefore, the trailing edge of the web in the wound core must be indexed accurately to enable the tabbing or labelling to be carried out automatically. Such indexing or maintenance of a constant orientation of the sometimes almost invisible trailing edge must be accomplished following high speed core rotation during winding and subsequent stoppage and delivery out of the winding apparatus and heretofor no satisfactory automatic tabbing arrangement has been provided.

OBJECTS AND SUMMARY OF THE INVENTION It is the object of the present invention to overcome the problems of the prior art and to provide a winding mechanism in which the tension of the web is accurately controlled from start up to finish of the winding of the core without rupture of the web or stretching the web beyond its elastic limit.

Another important object is to provide a winding start up that ensures that the web lies smoothly and accurately along the core without any creasing, folding or other unevenness.

Another important object is to eliminate all backlash problems in the web at severance.

Still another object is to support the core against bowing, distorting or collapse during the winding.

Again, it is an object to ensure that the length of web wound on the core accurately corresponds to the core length desired.

A further important object is to provide a winding apparatus to accomplish the aforesaid objects which is of relatively simple, inexpensive and highly reliable construction.

Again it is an object to ensure positive core delivery to and positive wound core ejection from the winding apparatus without damage to the core or product.

Again it is an object to provide positive core feed accurately timed to feed a fresh core to the winding apparatus immediately after ejection of a wound core regardless of the winding time required to wind the desired predetermined core length.

Still a further object is to provide for a positive wound core ejection immediately on cessation of winding and web severance regardless of the winding time required to wind the desired predetermined core length.

Again it is an object to provide positive wound core ejection as aforesaid in which the trailing edge of the wound web has a precise constant orientation and to deliver such ejected core to be labelled while presenting the wound core and the trailing edge of the wound web to the labelling mechanism always in the same desired predetermined orientation.

Still another important object is to provide core feed, wound core ejection, wound core transfer and labelling apparatus, all precisely co-ordinated regardless of winding time whereby the entire function of feeding, winding, ejection and tabbing of the core can be effected automatically and rapidly. Again, a further important object is to provide apparatus of such a nature which will be relatively simple, inexpensive and highly reliable construction.

According to the invention, in the winding operation, relative movement between a core and a rotatable surface or roller is first effected preferably by translation of the core towards the rotatable surface, to move same from a separated, loading and unloading position or station to an adjacent position to cause the core to nip the web of the parent roll against the rotatable surface at a point such that a free starting length of parent roll web hangs below the core. Such starting web length is then conformed around the core to initiate core winding and the core is rotated with limited torque to draw a length of web from the parent roll while winding same on the core. Thereafter the core and rotatable surface are separated, preferably again by translating the core away from the rotatable surface to provide or draw off a core length beyond the rotating surface and the core rotation is stopped and the web severed while controlling web backlash immediately adjacent to the core whereby the core length drawn beyond the rotating surface drops downwardly and forms the starting web length for the next succeeding core in the repeating of the winding cycle.

Further according to the invention, the rotating sur face against which the core nips the web is utilized as the means of measuring the length of web drawn from the parent roll as a result of core rotation and its rotation through a predetermined number of revolutions is utilized to signal core translation away from the rotating surface and cessation of core rotating surface and parent roll rotation.

Also according to the invention the parent roll rotation is controlled to provide an external drag after the parent roll has been accelerated to winding speed, the drag being regulated to decrease as the diameter of the parent roll decreases as the web is withdrawn therefrom to prevent the web from overfeeding and becoming slack which would result in folding or creasing due to the rotational inertia of the parent roll system, the drag however always being such that the tension in the web will not cause slippage of the core when the core has reached winding speed.

Further according to the invention, the core is supported sleeved on a mandril during winding for driving thereby through a torque limited clutch and means are provided for ejecting a wound core from the mandril and for sleeving a fresh core on the mandril, the ejection of the wound core being signalled following translation of the wound core to the loading-unloading station, stoppage of the mandril rotation and severance of the web adjacent to the wound core, and the arrival of the fresh core sleeved on the mandril signalling the translation of the mandril from the loading-unloading station to nip the web against the rotating surface.

Still further according to the invention, the arrival of the core adjacent to the web nipping position signals the conforming of the starting length of web around the core and rotation of the mandril, the parent roll and rotating surface having been released for rotation at this time.

Again according to the invention the conforming of the starting length of web around the core is accomplished by the use of an arrangement of circumferentially deflected and directed air jets without requiring the physical handling and potential impairment of the leading edge of such starting length.

According to the invention, in the core feeding, individual cores are isolated from a core stack at a loading station, translated while being supported free for axial movement into axial alignment with the winding mandril then moved axially to effect a sleeving of the core onto the mandril.

In this connection, according to the invention, the support means for the core during translation to the position of axial alignment with the mandril comprises a cradle, and the core is delivered axially onto the man dril by means of a piston operating axially through the cradle.

According to another aspect of the invention, the feed of cores from the core stack to the cradle is effected by arranging the cores to be delivered as a vertical stack, with the cores vertically aligned and providing a star wheel arrangement wherein the wheel is rotated on an axis offset from the vertically aligned cores and the spokes or prongs of the wheel being adapted to successively arrive at a position to block downward movement of the lowermost undelivered core and the weight of the cores above the blocking prong being sufficient to rotate the star wheel and allow delivery of the lowermost core, and means are provided to block star wheel rotation in the absence of a cradle in vertical registration with the core stack and to allow star wheel rotation on the bringing of a cradle into such vertical registration to effect delivery of the lowermost core to the cradle, the presence of the lowermost core in the cradle then blocking further star wheel rotation.

According to the invention, in the wound core ejection, the wound core is axially sleeved off the mandril with the severed trailing edge of the web in a predetermined orientation into an open clam moved into axial alignment with the mandril. The clam is then closed to deliver the wound core out of axial mandril alignment to the tabbing station while retaining the relative orientation of the wound core and clam whereby the tabbing is properly effected at the web trailing edge,

Further according to the feed and ejection aspect of the invention, the cradle and clam are connected to move in synchronization to successively feed a core and successively accept a wound core.

Further according to the invention in the tabbing operation, the tab delivering mechanism is actuated as a consequence of the movement of the wound core carrying clam to effect simultaneous advancement of the tab towards the wound core and advancement of the wound core towards the tab whereby tabbing is effected at a tabbing position intermediate of the starting position of both tab and wound core.

Also in accordance with this aspect of the invention, a tab is moved with a wiping motion to contact the trailing web edge on the wound core and move same in a direction to tighten the outermost layer of web prior to sealing of the tab to bridge across the trailing web edge and adjoining web surface.

Again, in connection with the tabbing according to the invention, the end tabs are mounted in precise sequential orientation on a carrier strip provided with a row of feed holes, and cog wheel means are provided to engage the holes in the carrier strip to provide positive advancement and accurate registration of the end tabs in position to be picked off by the tab delivery mechanism.

Further in accordance with the preferred embodiment of the invention, the tab delivery mechanism incorporates a vacuum head to pick off tabs from the carrier strip and additional air jet means are employed to lift the tab from the carrier strip and urge same towards the vacuum head as vacuum is applied thereto. Also during tab application the vacuum head is converted from a vacuum tab holding means to a positive air jet tab delivery means.

According to the tabbing aspect of the invention, the end tabs or labels are in the form of narrow elongated tabs having an adhesive carrying length to be adhered circumferentially of the wound core adjacent the center thereof in bridge across the trailing web edge to tack the trailing web edge to an under web surface, and a finger gripping portion free of adhesive, extending from the portion of the adhesive carrying length effecting the tacking down of the trailing web edge. These tabs are mounted in spaced parallel relation on the carrier strip with their lengths extending transversely of the strip length and the cog wheel is arranged to feed such strip and tabs laterally in a direction parallel to the length of the wound core to the tab pick up station and the tab delivery mechanism is adapted to move in its wiping action in a plane perpendicular to the length of the wound core.

Again, in accordance with the invention, the core pick up and transfer cradle mechanism, the wound core receiving, clamping and transfer mechanism, and the tab feeding and delivery mechanism are all positively mechanically interconnected which such positively inter-connected mechanisms are responsive in unison to signals associated with the winding apparatus, whereby on delivery of a wound core into the clam mechanism the cradle is actuated to deliver the lowermost core from the core stack to axial alignment with the mandril; the delivered wound core is transferred by the clam mechanism to the tabbing position and the tab applied and on delivery of a core onto the mandril the cradle is returned to pick up the next lowermost core, the clam is returned to receive the next wound core and the tabbing mechanism is returned to pick up the next tab.

These and other objects and features will become apparent from the following detailed description taken in conjunction with the accompanying drawings.

FIG. 1 is a perspective view partly broken away of an automatic core winding apparatus embodying the invention and showing the relationship of the mechanism such that a wound core is about to be ejected from the winding apparatus to the open wound core transfer clam and with a fresh core received in the transfer cradle.

FIG. 2 is a perspective view partly broken away of the apparatus of FIG. 1 taken from the opposite side of the apparatus.

FIG. 3 is a side elevational view partly broken -away of the winding apparatus and illustrating in dotted line the translational movement of the motor bracket.

FIG. 4 is a side elevational view of the winding apparatus taken from the opposite side to that illustrated in FIG. 3 with the motor bracket and mandril at the core loading and unloading station, some of the parts being omitted for the sake of clarity.

FIG. 5 is a view similar to FIG. 4 but illustrating in dotted line the movement of the motor bracket and winding mandril to the winding position and with the backlash rolls moved out of co-operation with the core co-operating metering roll.

FIG. 6 is an end elevational view looking towards the mandril end of the winding apparatus and illustrating the film guide and bracket and web severing knife.

FIG. 7 is an elevational view illustrating the position of the web guide relative to the core bearing mandril at the winding position and the air jets to direct the leading edge of the web led over the core co-operating roll in a wrapping motion around the core, the web severing knife being shown in a retracted position.

FIG. 8 is a view similar to FIG. 7 but illustrating the mandril translated to the core loading and unloading station after the core has been wound to draw out a further length of web extending between the core cooperating roll and the core and showing the web severing knife in extended severing position and the film guide swung clear of the mandril and core. FIG. 9 is a part vertical sectional, part elevational view showing the relationship of the core transfer apparatus and the winding apparatus showing the core ejector in the process of returning following the ejection of a wound core into the waiting clam.

FIG. 10 is a view similar to FIG. 9 but showing the core loader in'position immediately after delivering a fresh core from the core carrying cradle onto the winding mandril.

FIG. 11 is an enlarged broken-away elevational view of the core arrival sensing device associated with the mandril.

FIG. 12 is a part vertical sectional, part elevational view of the core handling apparatus and illustrating the relationship of the parts with the cradle at the core pick-up and receiving position and the clam at the core loading and unloading position and opened in preparation to receive a Wound core ejected from the winding apparatus, the view further showing the picker head at the tab pick-up position, the circled portion of which being also shown enlarged.

FIG. 13 is a view similar to FIG. 12 but showing the turret of the core feed apparatus rotated to bring the core carrying cradle to the core loading position and the wound core carrying clam to the tabbing position with the clam closed.

FIG. 14 is an elevational view showing the relationship between the main turret shaft, the scalloped cam on the star wheel shaft and the blocking counter cam with the cradle in core pick-up position.

FIG. 15 is a rear elevational view broken-away of the core transfer mechanism showing the tab feed and the picker head at tab pick-up position with the cradle in core pick-up position.

FIG. 16 is a side elevational view of the tabbing mechanism showing the picker head in solid line at the tab applying position to apply a tab to the wound core clamped in the clam.

FIG. 17A is a pneumatic schematic diagram of the film guide cylinder and mandril carrying motor bracket cylinder and the power valve control.

FIG. 17B is a similar diagram of the brake cylinder arrangement.

FIG. 17C is a similar diagram of the ejector cylinder arrangement.

FIG. 17D is a similar diagram of the core loading cylinder and jet core sensing cylinder arrangement.

FIG. 17E is a similar diagram showing the turret cylinder and roll clamp cylinder arrangement.

FIG. 17F is a similar diagram of the knife cylinder arrangement.

FIG. 17G is a diagram of the vacuum controlling power valve.

FIG. 18 is a schematic diagram of the air control circuit for operating the apparatus.

DETAILED DESCRIPTION OF THE DRAWINGS GENERAL With reference particularly to FIGS. 1 and 2, an automatic winding machine embodying the invention comprises a core feed or transfer mechanism generally designated at 1 for feeding a core to a winding apparatus generally designated at 2, accepting a wound core ejected from the winding apparatus 2 and transferring it to a tabbing station to have a tab applied thereto by a tabbing mechanism generally designated at 3 in FIG. 16. For fully automatic operation, the functioning of the mechanisms 1, 2 and 3 are inter-related to effect first a fresh core advance from a core supply to a loading section and the loading of the core onto the winding apparatus, the winding of the core with the web of material until the predetermined length of web material has been wound thereon, the ejection of the wound core out of the winding apparatus, the transfer of the ejected wound core to the tabbing apparatus and the tabbing thereof.

WINDING APPARATUS As shown in FIGS. 2 and 3 the winding apparatus 2 is carried by the main machine table 4 which carries spaced vertical plates 5 and 6. Extending through and journalled in the support plates 5 and 6 is a parent roll shaft 7 on which is mounted a parent roll 8 of the web or film to be wound on the cores and comprising, for example, a web of polyvinylchloride or polyethylene. The parent roll of web material 8 is secured to the parent roll shaft 7 for rotation therewith by any suitable means. For example, the shaft 7 may be a radially expandable shaft of the type employing a compressible rubber sleeve 9 expanded by an end fitting 10. Secured 0n the parent roll shaft 7 on the side of the plate 6 re mote from the parent roll is a brake drum 11 with which co-operates a drag brake 12 and a stoppage brake 13. The drag brake 12 comprises an arm pivoted at 14 and having an arcuate portion 15 encompassing a portion of the brake drum 11, the arcuate portion carrying a brake lining 16 of suitable friction material.

The stoppage brake 13 is fixed to pivot shaft 17 and has an arcuate portion 18 encompassing a portion of the brake drum l1 and carrying a suitable brake lining 19.

Mounted at the rear of the table is a shaft 20 supported in bearings 21 and carrying at one end a lever arm 22 fixed thereo, the lever arm is turn carrying an arm 23 on the end of which is mounted a roller 24 adapted to roll against the periphery of the parent roll 8. Mounted on the shaft 20 is a further lever arm 25 to which is attached a yoke 26 by means of a pin 27 adapted to fit in a selected hole 28 in the lever arm. Attached to this yoke is a chain 29 which passes under idler rolls 30 and 31 and connects to the lower end of a spring 32, the upper end of which is connected by means of a cable 33 passing over idler 33a to the end of a threaded rod 34 which passes through a laterally extending arm 35 carried by the drag brake 12 and is held in adjustable position by means of a nut 36, all as shown particularly in FIGS. 2 and 3.

Thus is will be seen that the roller 24 and the associated parts constitutes a parent roll diameter measuring or sensing device which on being pushed counterclockwise as is viewed in FIGS. 2 and 3 by the presence of a large diameter parent roll 8, displaces lever arm 25 counter-clockwise to apply tension to the spring 32 which in turn applies tension to the drag brake 12 through the cable 33 passing over the idler roll 33a and the threaded rod 34. The adjustment of the nut 36 provides adjustment of the tension applying the drag brake 12 for a given parent roll diameter. Mounted on the top of the plate 6 for longitudinal sliding movement is a bar 37 passing under guides 38. This bar 37 carries a vertical projection 39 which carries a threadably adjustable headed pin 40 arranged to contact the drag brake arm 35 when the bar 37 is slid to the rear of the table to lift the drag brake out of braking engagement with the parent roll brake drum 11. The parent roll shaft stoppage brake 13 is operated by an air cylinder 41 shown in FIG. 5 which has a piston 42 pivotally connected to the end of a lever arm 43 attached to the shaft 17. As shown particularly in FIGS. 1 and 4 the film or web W drawn off the parent roll is led around an idler spreading roll 44journalled betweenthe plate 5 and a bracket 45 mounted on the table 4 and over the top of a core co-operating and metering roll 46 carried on a shaft 27 extending through and journalled in the plates 5 and 6. The web spreading roll 44 is formed of rubber or the like and has outwardly directed left and right hand spiral grooves 441 and 451 formed therein which on rotation act to spread the web towards the end of the roll and eliminate longitudinal web creases. As illustrated in FIG. 4, the core co-operating and metering roll shaft 47 carries a brake drum 48 with which co-acts a stoppage brake 49 having a suitable brake lining 50. The brake 49 comprises an arm pivoted intermediate its length at 51 and operated by an air cylinder 52 having a piston 53 connected to the lower end 54 of the brake arm. As shown in FIGS. 2 and 3 the shaft 47 carries a smaller gear 55 presented at the side of the plate 6 opposite to the roll 46. The gear 55 meshes with rotation reducing gears 56 and 57 to drive a cam carrying gear 58. The cam carrying gear as shown in FIG. 3 is provided with roller cams 50 which on rotation of the gear 58 are adapted to contact the roller 60 of a pivoted control arm 61 for controlling the functioning of the apparatus as hereinafter described. It will be understood that the arrangement is such that the control arm 61 will be operated following a predetermined nunber of rotations of the core co-operating and metering roll 46 and such predetermined number of revolutions of the roll 46 will determine the length of the web W delivered over the metering roll. Hence by setting the cams 59 at appropriate locations on the cam carrying gear 58, a predetermined length of web feed before operation of the control arm 61 can be effected. As shown in FIG. 2, 3 and particularly, mounted towards the front of the table on a shaft 62 is a motor braket 63 having a depending arm 63a extending below the table 4 on which is mounted a motor 64. An upwardly extending arm portion 63b of the bracket 63 carries a hub 65 in which is journalled a shaft 66 best seen in FIG. 2. A portion of the shaft 66 extends to one side of the plates 5 and 6 with its axis parallel to the axis of the parent and core co-operating rolls 8 and 46 and constitutes the winding mandril 67 shown particularly in FIGS. 1 and 6 to 10.

The shaft 66 as shown in FIGS. 2 and 3 carries at the opposite side of the plates 5 and 6 a pully 68 and a brake drum 69. A belt 70 connected between the pully 68 and a motor pully 71 provides the drive from the motor to the mandril 67.

The motor bracket 63 is adapted to be rocked by an air cylinder 72 pivotally supported at 73 and having a piston 74 pivotally connected to the motor bracket as shown particularly in FIG. 5. Also as shown in FIG. 5 the pivotal air cylinder 72 carries an arm 75 adapted to engage a threadably adjustable screw 76 carried by a lever arm 77 connected to a roller carrying arm 78 pivoted at 79. The roller carrying arm carries a plurality of rollers 80 adapted to ride on the upper surface of the core co-operating and metering roll 46 when the motor bracket is swung away from the roll 46 to the solid line position of FIG. 5 and to the position of FIG. 4 to clear the arm 75 from the adjusting screw 76. This position of the motor bracket 63 locates the mandril 67 in what will hereinafter be referred to as the core loading and unloading station, a station away from the core cooperating and metering roll 46. On the other hand, when the motor bracket 63 is pulled or raised to bring the mandril 67 to the dotted line position shown in FIG. 5, adjacent to the roll 46, a position hereinafter referred to as the winding position, the arm 75 operates to lift the rollers 80 clear of the roll 46.

Co-operating with the brake drum 69 carried by the shaft 66 of which the winding mandril 67 forms a part, is a brake 81 carrying suitable brake lining 82 mounted on a rocker arm 83 connected to the piston 84 of an air cylinder 85 shown in FIG 3.

As the motor bracket swings to bring the mandril to the winding position it is arranged to contact a limit valve LV-Z to energize the motor 64 and on being swung to move the mandril to the core loading and unloading station is adapted to engage a further limit valve LV-4 for purposes as will hereinafter appear, the limit valves being diagrammatically illustrated in FIG. 5.

As illustrated in FIG. 1 and particularly in FIG. the mandril 67 is adapted to have a core C on which web W from the parent roll 8 is adapted to be wound, sleeved thereon. Normally this core C is of hollow tubular construction being formed for example of spirally wound cardboard although its actual construction is immaterial from the standpoint of the present invention. As shown in FIG. 10 and also FIG. 9, the mandril 67 carries a clutch 88 in the form of a pair of spring loaded balls 89 adapted to engage he interior of the core C to provide limited torque transfer between the mandril and core. Carried on a bracket 90 is a retractable core sensing device generally designated at 91 shown diagrammatically in FIG. 10 and illustrated in FIG. 1 and particularly FIG. 11. As shown in FIG. 11 the core sensing device coprises a nozzle 92 normally closed by a ball 93 and attached to the piston 94 'of an air cylinder 95. The nozzle 92 is connected in an air control circuit hereinafter more fully described and its normal position with the mandril at the loading and unloading station is that shown in FIG. 10 with the ball 93 located in the path of a core C being sleeved on the mandril. Upon the core C displacing the ball 93 to open the nozzle 92, an air signal is generated in the air control circuit hereinafter more fully described with reference to FIGS. 17A to 17G and 18 to effect commencement of the operation of the winding apparatus 2 and retraction of the core sensing device 91.

For purposes of explanation it will be understood at this point that insofar as the operation of the winding apparatus 2 is concerned, the core carrying mandril will be translated from the loading and unloading station of FIG. 1 to the winding position shown in dotted lines in FIG. 5. It will be understood that prior to the initiation of the winding apparatus, a length of web W will have been drawn off the parent roll 8 led under the idler roll 44 and over and across the top of the core cooperating roll 46 with the free web end hanging downwardly to adjacent the bottom of the roll 46 so that when the mandril reaches the winding position of FIG. 5 and FIG. 7 it will nip the web W against the roll 46 above the free end thereof.

As shown particularly in FIGS. 6, 7 and 8 mounted on the motor bracket shaft 62 is a lever arm 96 which carries an elongated part circular film guide 97. An air cylinder 98 pivoted at 99 has a piston 100 connected to the lower end of the lever arm 96 to swing the film guide 97 to follow the mandril from the loading and unloading station illustrated in FIG. 8 to the winding position illustrated in FIG. 7. In the winding position of FIG. 7, the film guide 97 forms with the core C a narrow arcuate path 101 around a substantial portion of the periphery of the core. Arranged below the core carrying mandril at the winding position is a channel 102 carrying tube 102a running along the length of the mandril having jet openings 103 therein through which air jets initiated by the motor bracket in the up position making control valve 104 (FIG. 5) are adapted to be directed against the side of the free hanging web end away from he core to direct such web end up and through the narrow arcuate passage 101 to force such web end in a wrapping motion around the core C.

It will be understood that the air cylinder 98 will be actuated in conjunction with the air cylinder 72 to move the film guide 97 in conjunction with the mandril 67 to the winding position for initiation of the winding. It will be also understood that the air cylinders 41, 52 and 85 will be operated to effect release of the brakes on the parent roll shaft 7, the core co-operating and metering roll shaft 47 and the shaft extension 66 of the mandril 67. Further, as the core C moves into web nipping position at the winding position, the motor bracket 63 is arranged to contact the end of the slide bar 37 to actuate same rearwardly against the laterally extending arm 35 of the drag brake 12 to lift the drag brake out 

1. Apparatus for producing a roll of a predetermined length of web material wound onto a hollow core comprising spindle means for mounting a parent web roll for rotation, a core co-operating roll mounted for rotation over which web from a parent roll is adapted to be drawn, a mandril adapted to receive a core sleeved thereon mounted for rotation on an axis parallel to the axis of rotation of said core co-operating roll and for translation between a core loading and unloading station away from said core co-operating roll, and a winding position adjacent said core cooperating roll; means for rotating said mandril to rotate a core sleeved therein, means for translating said mandril, clutch means interposed between said rotating means and such sleeved core for providing limited torque transfer between said rotating means and such sleeved core, transfer means for transferring a core from a stack of cores into axial alignment with said mandril with said mandril translated to said core loading and unloading station, means for delivering an axially aligned core onto said mandril, means responsive to the delivery of a core onto said mandril to effect translation of said mandril to said winding position to cause the core to nip a web drawn over said core co-operatIng roll against said roll, with the free end of the web hanging below the core, means to effect displacement of the hanging free web end in a wrapping movement about the core, means responsive to the translation of said mandril to said winding position to actuate said mandril rotating means to effect winding of the nipped and wrapped web on the core, means responsive to the winding of a predetermined length of web on the core to effect actuation of said mandril translation means to return said mandril to said loading and unloading station and to effect deactivation of said mandril rotating means, brake means for braking said mandril and parent roll spindle on deactivation of said mandril rotating means to bring web feed to a stop with the return of said mandril to said loading and unloading station, means for severing the web immediately adjacent to the wound core on the mandril with same at said loading and unloading station and means for ejecting a wound core axially off said mandril following web severance.
 2. Apparatus as claimed in claim 1 in which brake means are provided to effect stoppage of core co-operating roll rotation simultaneously with the stoppage of web feed.
 3. Apparatus as claimed in claim 2 in which said core co-operating roll comprises a metering roll and the means responsive to the winding of a predetermined length of web wound on the core comprises means actuated by the rotation of said metering roll through a predetermined number of revolutions.
 4. Apparatus as claimed in claim 1 in which drag brake means are provided to provide a drag braking to said parent roll mounting spindle following commencement of core winding, and means responsive to the diameter of the parent roll to regulate said drag brake means to effect a progressive reduction in braking as the diameter of the parent roll decreases.
 5. Apparatus as claimed in claim 1 in which said means to effect displacement of the hanging free web end in wrapping movement about a core on said mandril with the core moved to said winding position comprises a web guide presenting a longitudinal concave deflecting surface extending longitudinally parallel to the mandril axis, said web guide being movable between a web guiding position adjacent to said mandril with said mandril moved to advance a core to said winding position to provide a narrow curved air path between said plate and an appreciable extent of the periphery of a core on the mandril on the side of the core opposite to said core co-operating roll and a retracted position clear of the translation path of said mandril and core in moving from said winding position to said loading and unloading stations, and means for directing an air blast against the free hanging web end and up through said narrow curved path to direct the web end into said path and against the core periphery.
 6. Apparatus as claimed in claim 5 in which means are provided to move said guide to said web guiding position and retracted positions simultaneously with the translation of said mandril to said winding position and to said loading and unloading station respectively.
 7. Apparatus as claimed in claim 1 in which detector means are provided to detect the absence of a web normally led over said core co-operating roll in position to be nipped by a core on said mandril when translated to said winding position; said detector means being connected to a control circuit arranged to prevent mandril rotation when the web is absent.
 8. Apparatus as claimed in claim 1 in which detector means are provided to detect the presence of a web wrapped around said core co-operating roll, said detector means being connected to a control circuit arranged to prevent mandril rotation on detection of co-operating roll web wrapping.
 9. Apparatus as claimed in claim 1 in which means are provided to prevent backlash of a severed web away from the point of severance and over said core co-operating roll, said means comprising a plurality of rollers, means mounting said rolleRs for movement towards and from the upper surface of said core co-operating roll and means responsive to the translation of said mandril to said loading and unloading station to effect movement of said roller mounting means to bring said rollers towards said upper roll surface and into engagement with a web led thereover and responsive to the translation of said mandril towards said winding position to effect movement of said roller mounting means to move said rollers away from said upper roll surface.
 10. Apparatus as claimed in claim 4 in which means are provided to release said drag brake means during initial rotation of said mandril at the commencement of the winding of the web on a core sleeved on said mandril.
 11. Apparatus as claimed in claim 1 in which said mandril translating means is resiliently displaceable to permit mandril displacement away from said core co-operating roll under accumulation of web material on a core on the mandril during winding.
 12. Apparatus as claimed in claim 11 in which drag brake means are provided to engage and brake said parent roll spindle, resilient means urging said drag brake means into spindle braking engagement and means responsive to mandril translation to bring an empty core to said winding position to displace said drag brake means against the action of said resilient means out of spindle braking engagement during initial winding of a web on the core and to release said drag brake means for braking engagement when a pre-determined web build up on the core has occurred.
 13. Apparatus as claimed in claim 12 in which parent roll diameter sensing means are provided to control said resilient means to regulate drag braking pressure when said drag brake means is in braking engagement to effect reduction of drag braking pressure on decrease of parent roll diameter.
 14. Apparatus as claimed in claim 1 in which said mandril translating means comprises an air cylinder and said means responsive to the delivery of a core onto the mandril to effect actuation of said mandril translating means comprises an air control circuit for said air cylinder including a core detecting air control device, air cylinder operated means mounting said core detecting device for movement between a core detecting position projecting onto the path of a core being delivered onto said mandril, and a retracted position clear of the path of mandril translation, said device being actuated by a delivered core to control said air circuit to effect operation of said air cylinder mounting means to retract said core detecting device and operation of said mandril translating cylinder to translate said mandril from said loading and unloading station to said winding position.
 15. Apparatus as claimed in claim 14 in which said means for delivering a core onto said mandril is an air operated ram movable between a retracted position and an extended core delivering position, and said air control circuit is connected to actuate said ram to retract same from said core delivery position in response to said core detecting device detecting a delivered core on said mandril.
 16. Apparatus as claimed in claim 14 in which said brake means are air operated and said air control circuit is connected to control said air operated brake means to effect release of said brake means from mandril and parent roll spindle braking engagement as a consequence of said detecting device detecting a core on said mandril and air control means associated with said air circuit and responsive to the winding of a predetermined length of web for effecting application of said brake means.
 17. Apparatus as claimed in claim 14 in which said means to effect displacement of the hanging free web end in wrapping movement about a core on said mandril with the core moved to said winding position comprises a longitudinal arcuate deflector plate, air cylinder operated means mounting said deflector plate for movement between an operative position adjacent to and extending parallel to the axis of said mandriL and on the side thereof opposite to said core co-operating roll to define with a core on the mandril, a narrow curved air path around an appreciable length of the core periphery when the mandril is in the winding position, and a retracted position clear of the path of translation of said mandril, and means to direct air against the free hanging web end and up through said curved air path, said air cylinder operated deflector plate being connected in said air control circuit and being controlled by said core detecting device to move to said operative position upon detection of a core on said mandril and translation of said mandril to said winding position.
 18. Apparatus as claimed in claim 14 in which said means for severing the web is carried by an air cylinder under control of said air control circuit for movement towards and from web severing position and said air control circuit includes control means operated as a consequence of mandril translation from said winding position to said loading and unloading station to effect movement of said severence means to said web severing position.
 19. Apparatus as claimed in claim 18 in which further air circuit control means are provided responsive to movement of said web severing means to said web severing position to effect retraction of said web severing means away from said web severing position.
 20. Apparatus as claimed in claim 19 in which said means for ejecting a wound core axially off said mandril comprises an air operated ejector ram under control of said air control circuit, said ejector ram being operated by said further air circuit control means upon retraction of said web severing means from said web severing position to eject a wound roll, an ejector air control means in said air control circuit responsive to the movement of said ejector means to eject a wound core in return said ejector in preparation for the ejection of a subsequent wound core.
 21. Apparatus for winding web from a parent roll onto a core comprising a rotatable core co-operating roll over which the free end of a web from a parent roll is adapted to be drawn and allowed to hand downwardly, means for mounting a core for rotation, said core mounting means being movable between a station removed from said core co-operating roll and a winding position to bring the core into web nipping relation with said core co-operating roll to nip the web along a line above said free web end, means for wrapping the free end around the core at said winding station, means for rotating the core to effect the winding of the wrapped web onto the core to draw off a length of web from the parent roll, means for moving the core mounting means to said station following winding to draw off a further length from the web extending between said core co-operating roll and said station, and means to sever the web adjacent to the core at said station whereby said further length of web is free to fall away and constitute the free end of the web from the parent roll drawn over and hanging down from the core co-operating roll for presentation to the next succeeding core to be wound.
 22. Apparatus for winding a predetermined length of web material onto a hollow core comprising spindle means for mounting a parent web roll for rotation, a core co-operating roll mounted for rotation over which the free end of the web from a parent roll mounted on said spindle means is adapted to be drawn and allowed to hang downwardly, a mandril adapted to receive a core sleeved thereon mounted for rotation on an axis parallel to the axis of rotation of said core co-operating roll and for translation between a loading and unloading station away from said core co-operating roll and a winding position adjacent to said core co-operating roll whereby a core sleeved thereon is adapted to nip the downwardly hanging web against said core co-operating roll along a line above the free web end, means for translating said mandril between said station and said winding position, means for operating said Translation means to translate said mandril to said winding position, means for directing the free end of a web nipped by a core at said winding position in a wrapping motion around the core, means for rotating said mandril when same is at said winding position to effect the winding of the wrapped web onto the core to draw off a length of web from the patent roll, clutch means to provide limited torque transfer between said rotating means and the core sleeved on said mandril, means for operating said translation means to translate said mandril from said winding position to said station following winding of the core to draw off a further length of web from the parent roll extending beyond said core co-operating roll to said station, means for severing the web adjacent to the core at said loading and unloading station whereby the further length of web extending beyond said core cooperating roll drops downwardly to constitute, for the winding of a subsequent core, the free end of the parent roll web drawn over the core co-operating roll and allowed to hang downwardly.
 23. Apparatus as claimed in claim 22 in which said mandril is mounted for rotation on a pivotally mounted support swingable about its pivot to move said mandril between said loading and unloading station and said winding position, and said means for translating said mandril comprises air cylinder means for swinging said support about its pivot and an air control circuit for said air cylinder.
 24. Apparatus as claimed in claim 23 in which said means for rotating said mandril comprises a driving motor, and means are provided for energizing said motor upon swinging of said pivoted mandril support to translate said mandril to said winding position and to de-energize said motor upon swinging of said pivoted mandril support to translate said mandril away from said winding position.
 25. Apparatus as claimed in claim 24 having means for measuring the length of web wound on a core sleeved on said mandril, and air control means actuated by said web measuring means and included in said air control circuit to actuate said air cylinder means to swing said mandril away from said winding position upon completion of the winding of a predetermined web length.
 26. Apparatus as claimed in claim 25 in which said web measuring means comprises means actuated by rotation of said core co-operating roll and operative after a predetermined number of revolutions of said core co-operation roll to actuate said air control means.
 27. Apparatus as claimed in claim 26 having first brake means for braking said motor and second brake means for braking said parent roll spindle, and means for applying said brake means following winding of a predetermined length of web on the core to bring said motor and mandril driven thereby and said parent roll spindle to a substantially simultaneous stop coincident with said mandril arriving at said loading and unloading station.
 28. Apparatus as claimed in claim 27 having third brake means for braking said core co-operating roll, and means for applying said third brake means.
 29. Apparatus as claimed in claim 28 in which said means for applying said first, second and third brake means comprises first, second and third air cylinder means controlled by said air control circuit, and said air control means actuated by said web measuring means is arranged upon activation thereby to operate said first, second and third air cylinder means for brake application.
 30. Apparatus as claimed in claim 29 in which air control means are provided to operate coincidentally with translation of said mandril from said loading and unloading station towards said winding position to operate said first, second and third air cylinder means for brake release.
 31. Apparatus as claimed in claim 27 in which the means for applying said second brake means is arranged to provide a variable braking effort, and means are provided to measure parent roll diameter to control said second brake applying means to reduce braking effoRt as the parent roll diameter diminishes.
 32. Apparatus as claimed in claim 27 having drag brake means for braking said parent roll spindle, means responsive to the arrival of said mandril at said winding position to release said drag brake means until a core sleeved on said mandril has accumulated a plurality of web layers during winding, and means to measure parent roll diameter to control said drag brake means to reduce drag braking effort as the parent roll diameter diminishes.
 33. Apparatus as claimed in claim 22 in which said means for directing the free end of a web nipped by a core at said winding position in a wrapping motion around the core comprises a longitudinal arcuate deflector plate, means mounting said deflector plate for movement between an operative position adjacent to and extending parallel to the axis of said mandril and on the side thereof opposite to said core co-operating roll to define with a core on the mandril, with said mandril at said winding position, a narrow curved air path around an appreciable length of the core periphery and a retracted position clear of the path of translation of said mandril, and means to direct air against the free hanging web end and up through said curved air path.
 34. Apparatus as claimed in claim 33 in which said means mounting said deflector plate comprises air cylinder means and an air control circuit therefor arranged to actuate said air cylinder means to move said deflector plate to said operative position coincidentally with the movement of said mandril to said winding position and to retract said deflector plate coincidentally with the movement of said mandril to said loading and unloading station.
 35. Apparatus as claimed in claim 22 having means to prevent web backlash over the top of said core co-operating roll upon severing of the web adjacent to the core at said loading and unloading station, said backlash preventing means comprising roller means movable between an operating position to engage a web drawn over said core co-operating roll and hold same thereagainst and an inoperative position clear of the web, and means responsive to mandril translation to effect movement of said backlash preventing roll means to said inoperative position with said mandril at said winding position and to said operative position with said mandril at said loading and unloading station.
 36. Apparatus as claimed in claim 35 in which said severing means comprises a longitudinal heated element reciprocally mounted for movement towards and from the web at a point adjacent to the core with said mandril translated to said loading and unloading station to draw off said further length of web, and means responsive to the arrival of the mandril from said winding position to said loading and unloading position to move said heated element into contact with said web and means responsive to the movement of said heated element to web severing position to retract said heated element.
 37. Apparatus as claimed in claim 36 in which means are provided to eject a wound core from said mandril and means for operating said ejecting means in response to the retraction of said heated element.
 38. Apparatus as claimed in claim 22 in which said means operating said translation means to effect translation of said mandril from said loading and unloading station to said winding position is responsive to the sleeving of a core onto said mandril.
 39. In a winding apparatus, means for rotatably mounting a parent roll of web material, a mandril adapted to receive a hollow core sleeved thereon, means for driving said mandril in rotation, clutch means interposed between and providing limited torque transfer between said driving means and a core on said mandril, a core co-operating roll mounted for rotation, said core co-operating roll and mandril being relatively movable between an adjacent co-operating web feeding position to feed web led from a parent roll between said core co-operating roll and a core on said mandril to Be nipped thereby and a separated position to allow for sleeving of a core on and removal of a core from said mandril, and means for guiding the leading edge of a web nipped by said core co-operating roll and a core on said mandril around the core.
 40. In a winding apparatus as claimed in claim 39 in which said web leading edge guide means comprises an air deflector arranged to define with a core on said mandril with the mandril and core co-operating roll at the feeding position, a narrow arcuate path around an appreciable extent of the core periphery, and air jet means for directing air through said path arranged to deliver the leading edge of the web into and through said path under air pressure.
 41. In a winding apparatus claimed in claim 39 means for measuring the length of web wound on a core driven by said driving means, and means responsive to said measuring means measuring a a predetermined length of web, to effect interruption of the drive of said driving means and braking of said mandril to stop the rotation of same, and means for severing the web adjacent to the core on stoppage of said mandril.
 42. In a winding apparatus as claimed in claim 41, means for effecting relative movement of said mandril and core co-operating roll, said latter means being responsive to said measuring means to effect relative mandril and core co-operating roll separation prior to web severance.
 43. In winding apparatus is claimed in claim 42, means responsive to the operation of said severing means to eject a wound core from said mandril.
 44. In winding apparatus as claimed in claim 43, means responsive to the sleeving of a fresh core onto said mandril for effecting relative movement of said mandril and core co-operating roll to said web feeding position.
 45. In winding apparatus as claimed in claim 39, a rotatably mounted resilient web spreading roll around an appreciable peripheral portion of which web from a parent roll led to said core co-operating roll is adapted to be led, said web spreading roll having on opposite sides of the centre thereof outwardly directed left and right hand spiral grooves formed therein. 